Design and analysis of deep drawing die for brass socket by using finite element analysis.

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DESIGN AND ANALYSIS OF DEEP DRAWING DIE FOR

BRASS SOCKET BY USING FINITE ELEMENT ANALYSIS

NORHIDAYAH BT HASHIM

B050910016

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

DESIGN AND ANALYSIS OF DEEP DRAWING DIE FOR BRASS

SOCKET BY USING FINITE ELEMENT ANALYSIS

This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering

(Manufacturing Design)

by

NORHIDAYAH BT HASHIM B050910016

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

TAJUK: Design and Analysis of Deep Drawing Die for Brass Socket by using Finite Element Analysis

SESI PENGAJIAN: 2011/ 12 Semest er 2

SayaNORHIDAYAH BT HASHIM

mengaku membenarkan Laporan PSM ini disimpan di Perpust akaan Universit i Teknikal Mal aysia Mel aka (UTeM) dengan syarat -syarat kegunaan sepert i berikut :

1. Laporan PSM adal ah hak mil ik Universit i Teknikal Mal aysia Mel aka dan penul is. 2. Perpust akaan Universit i Teknikal Mal aysia Mel aka dibenarkan membuat sal inan unt uk

t uj uan pengaj ian sahaj a dengan izin penul is.

3. Perpust akaan dibenarkan membuat sal inan l apor an PSM ini sebagai bahan pert ukaran ant ara inst it usi pengaj ian t inggi.

4. **Sil a t andakan (√)

PENYELIA PSM

Tarikh: _______________________

** Jika Laporan PSM ini SULIT at au TERHAD, sil a lampirkan surat daripada pihak berkuasa/ organisasi berkenaan dengan menyat akan sekal i sebab dan t empoh l aporan PSM ini perl u dikelaskan sebagai

Al amat Tet ap:

(Mengandungi makl umat TERHAD yang t el ah dit ent ukan ol eh

organisasi/ badan di mana penyel idikan dij al ankan)

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DECLARATION

I hereby, declared this report entitled “Design and Analysis of Deep Drawing Die for Brass Socket by using Finite Element Analysis” is the results of my own research

except as cited in references.

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APPROVAL

This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfilment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing Design). The member of the supervisory committee is as follow:

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ABSTRAK

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ABSTRACT

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DEDICATION

For My Father, Hashim Bin Yunus & all my family especially my youngest brother,

Mohd Hafizudin Bin Hashim who is always beside me either in a difficult situation or

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ACKNOWLEDGEMENTS

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2.2.7 Drawn Cup Height 18

2.2.8 Drawn Cup Diameter 21

2.3 Previous Research 22 2.4 Finite Element Analysis (FEA) 24 2.4.1 Explicit Dynamic Analysis 27 3. METHODOLOGY 31 3.1.5 Phase 4: Report Submission & Presentation 34

3.2 Process to Produce Brass Socket 34

4. PROCEDURE OF EXPLICIT DYNAMIC ANALYSIS USING ANSYS 50 4.1 Create Analysis System 50 4.5.2 Setting Contact Conditions Manually 65

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LIST OF TABLES

3.1 Process to produce brass socket 35

4.1 Result of total deformation as a tabular data 83

5.1 Tabular data on displacement 85

5.3 Result of shear stress as a tabular data 91 5.4 Tabular data on displacement 92

5.6 Result of shear stress as a tabular data 98 5.7 Tabular data on displacement 99

5.9 Result of shear stress as a tabular data 106

6.1 Differences between specific value and analysis value of height 121

6.2 Differences between maximum and minimum value of shear stress 122

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LIST OF FIGURES

1.1 Deep drawing concept 2

2.1 Schematic illustration of deep drawing die 8 2.2 Shcematic of conventional deep drawing process; (a) Initial blank

(b) Drawing in process 9 2.3 Forming by flexible media; (a) Hydromechanical deep drawing

(b) High-pressure Hydroforming 10 2.4 Combined Hydroforming, joining and trimming of sheet metal parts

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4.1 Windows for attaching geometry from SolidWorks 2010 file to the system 54 4.2 Engineering Data workspace 56 4.3 Length unit option before start DesignModeler workspace 57 4.4 DesignModeler workspace 58 4.5 PUNCH changes the Stiffness behavior 59 4.6 DIE changing the Stiffness behavior 60

4.7 PLATE changing the Stiffness behavior 61 4.8 Frictional contact region for deep drawing die analysis 64 4.9 Manual contact region for deep drawing die analysis 65 4.10 Meshing option in Mechanical application 67 4.11 Meshing result for deep drawing die analysis 69 4.12 Analysis setting for deep drawing die analysis 70 4.13 Fixed support for deep drawing die analysis 71 4.14 Displacement setting for deep drawing die analysis 73 4.15 Solution Information in Worksheet 74 4.16 Graph of time increment 75 4.17 Graph of energy conservation 76 4.18 Graph of momentum summary 77 4.19 Graph of energy summary 78 4.20 Mechanical Application for Total Deformation 79 4.21 Result of total deformation as an analysis structure 81 4.22 Result of total deformation as a graph displacement versus time 82

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5.11 Graph displacement versus time 99

5.12 Result of total deformation as an analysis structure 100

5.13 Result of total deformation as a graph displacement versus time 101

5.14 Solver output of conceptual design C 103

5.15 Result of shear stress as an analysis structure 104

5.16 Result of shear stress as a graph stress versus time 105

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LIST OF ABBREVIATIONS

JBSB - Jati Beringin Sdn.Bhd. TNB - Tenaga Nasional Berhad TMB - Telekom Malaysia Berhad FEA - Finite Element Analysis

DIN - Deutsches Institut fur Normung, German Institute for Standardization

CES - Canbridge Education Selector 3D - Third Dimensional

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CHAPTER 1 INTRODUCTION

This first chapter will discuss about the introduction of the deep drawing die for producing the brass socket of TNB’s pole with different height at Jati Beringin Sdn. Bhd. (JBSB). In this part, the briefing of the background, problem statement, objectives, scope, and structure of the research are discussed.

1.1 Backgrounds

1.1.1 Company

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strong company. Until September 2011, JBSB already has a paid up capital of RM1.5 millions.

1.1.2 Deep Drawing Die

Deep drawing dies in Jati Beringin Sdn. Bhd. (JBSB) is used to produce the brass socket of TNB’s pole with different height that is 7.5meters (m), 9.0m and 10.0m. Actually, deep drawing die has used two different types of concept in producing the brass socket that is drawn from the plate into the cup and drawn from the cup into the cup. The deep drawing concepts used in producing brass socket are shown in figure 1.1.

Drawn from plate into cup

Drawn from the cup into the cup Figure 1.1: Deep drawing concept

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1.2 Problem Statement

Deep drawing is one of the most important processes for forming sheet metal parts. It is widely used for mass production of hollow shapes in the packaging industry, automotive industry, etc. Deep drawing is a tensile-compressive forming of a sheet blank (or, depending on the material, also of foils or plates) to a hollow body open on one side or the forming of a pre-drawn hollow shape into another with a smaller cross-section without an intentional change in the sheet thickness.

Previously, the deep drawing concepts for producing the brass socket have been mentioned in section 1.1.2 that is drawn from the plate into the cup and drawn from the cup into cup such as drawn from the cup with 20mm diameter into the cup with 19mm diameter. Actually, to produce the brass socket need eight steps in detailed. Step one has used the concept one that is drawn from the plate into cup. Step two until six has used the concept to that is drawn from the cup into the cup. Step seven is removed the wrinkling and tearing that occurred. The last step is making the thread on the brass socket before it's ready to pack.

The major problem for this research is related to the processes itself in producing the brass socket. This means that, if the processes take a long time to complete, the productivity is low and the cycle time is increased. Because of that, it requires more than five stamping machines and manpower to run each of the machines. The company wants to reduce the usage of stamping machines in producing the brass socket. That's why, this research is necessitate to overcome the difficulty.

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1.3 Objectives

The objectives of this research are:

(a) Investigate the design parameters of deep drawing dies.

(b) Analyze the deep drawing dies using Finite Element Analysis (FEA). (c) Propose new design of deep drawing dies.

1.4 Scope

Few necessary elements must be considered to guarantee the objectives of this research achieved. Besides that, the deep drawing die is analyzed by using Finite Element Analysis (FEA) and also studied and do research about the process of a brass socket making to identify which process can be reduced. The scopes of this research are as follows:

(a) Investigate the deep drawing process base on literature study from many sources.

(b) Analyze the existing process of making brass socket and identify which process can be reduced for new deep drawing die.

(c) Analyze the new deep drawing die designs by using Finite Element Analysis (FEA) from ANSYS software with actual specification from the industry of a brass socket making.

1.5 Structure of the Research

Chapter 1 covers the introduction of the research with looking at problem statement,

objective and scope of the research. The methodology of this research also clarifies

momentarily from PSM I in semester 1 until PSM II in semester 2. Besides that, the

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Chapter 2 consists of literature review which covering the basic principal of Finite

Element Analysis (FEA) and also the parameters of designing a deep drawing die.

Besides that, the deep drawing process in producing the brass socket also explains in

detailed in this chapter. Thus, the deep drawing die is made from a variety of materials

and the importance of material influencing the performance of the deep drawing die will

be covered in this chapter. Also covered in this chapter is the several related research

journals that used to summaries about the overall work related to the deep drawing die.

Chapter 3 contains a methodology of the research which is explained the flow of the

whole research had been done. Planning is a part of project management, which

relates to the use of schedules such as Gantt charts to plan and subsequently report the progress of the research. In this chapter, all progress has been divided into five basic phases which is consist of Planning, Concept Development, Details design, Analysis and refinement, Report submission and presentation.

Chapter 4 covers the procedure of the analysis by using ANSYS Workbench 12.0. In

this chapter, the detail procedure will be reported as the most common method used in analyzing the brass deformation and fixturing forces by using Finite Element Analysis (FEA). Based on this analysis, the deep drawing defect for brass socket also can be found and reduce simultaneously. Besides that, the step to interpreting the result

from the software also will be covered in this chapter.

Chapter 5 continues the discussion on the result that obtained from the simulation. By using Explicit Dynamic Analysis by using ANSYS software, the result of the Finite Element Analysis (FEA) for the new design will be compared with the current design. From the result, the reducing process of deep drawing die in producing the brass socket will be discussed directly.

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1.6 Gantt Chart

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CHAPTER 2 LITERATURE REVIEW

In this second chapter, Literature review is to review the critical points of current knowledge on this particular project. In this chapter, also discusses the study that will be related to the project would be exercised. Besides, the project must be carried out with the theory, observation, recitation, understanding and documentations that related to how to design and analyze a lifting mechanism of deep drawing dies for brass socket or any related details. Therefore, it is necessary to achieve objectives of the project in more effectiveness and perfect.

2.1 Deep Drawing Process

2.1.1 Definition